CN111592368A - Rapid forming method of complex special-shaped refractory material - Google Patents
Rapid forming method of complex special-shaped refractory material Download PDFInfo
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- CN111592368A CN111592368A CN202010509818.1A CN202010509818A CN111592368A CN 111592368 A CN111592368 A CN 111592368A CN 202010509818 A CN202010509818 A CN 202010509818A CN 111592368 A CN111592368 A CN 111592368A
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/66—Monolithic refractories or refractory mortars, including those whether or not containing clay
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/001—Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/08—Producing shaped prefabricated articles from the material by vibrating or jolting
- B28B1/087—Producing shaped prefabricated articles from the material by vibrating or jolting by means acting on the mould ; Fixation thereof to the mould
- B28B1/0873—Producing shaped prefabricated articles from the material by vibrating or jolting by means acting on the mould ; Fixation thereof to the mould the mould being placed on vibrating or jolting supports, e.g. moulding tables
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/54—Producing shaped prefabricated articles from the material specially adapted for producing articles from molten material, e.g. slag refractory ceramic materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y70/00—Materials specially adapted for additive manufacturing
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
- C04B35/101—Refractories from grain sized mixtures
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
- C04B35/56—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
- C04B35/565—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on silicon carbide
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/349—Clays, e.g. bentonites, smectites such as montmorillonite, vermiculites or kaolines, e.g. illite, talc or sepiolite
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/42—Non metallic elements added as constituents or additives, e.g. sulfur, phosphor, selenium or tellurium
- C04B2235/428—Silicon
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
- C04B2235/602—Making the green bodies or pre-forms by moulding
- C04B2235/6026—Computer aided shaping, e.g. rapid prototyping
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Mold Materials And Core Materials (AREA)
Abstract
The invention relates to a preparation method of a rapid forming complex special-shaped refractory material, which is characterized by comprising the following steps: the method for quickly forming the complex special-shaped refractory material has the characteristics of quickness and high efficiency in the aspect of serving the complex special-shaped refractory material in the manufacturing aspect by vibration forming, and has the advantages of high specific strength because a mold for 3D printing the sand mold has the characteristic of high specific strength, good collapsibility and no structural stress release when being used as a lost mold, and obvious advantage in improving the manufacturing capability of the refractory material with the complex special-shaped inner cavity.
Description
Technical Field
The invention relates to a preparation process of a refractory material, and mainly provides a method for quickly forming a complex special-shaped refractory material.
Technical Field
Refractory materials are important materials indispensable for serving high temperature industries. Due to the defects of the preparation process, the products which are widely applied at present are mainly standard products and non-standard products with more standard shapes, such as bricks, plates, columns, pipes and the like, and the refractory products with more complex shapes are less applied.
The complex special-shaped refractory material die is prepared by the traditional process, the manufacturing period is long, the manufacturing precision is poor, and the requirements of complex and variable special-shaped products cannot be met. 3D printing has unique advantages in the aspects of faithful product design and rapid forming, and is a key means for improving the manufacturing level and competitiveness of the traditional industry.
The patent "CN 106083074B" relates to the use of Al2O3-ZrO2Ceramic raw material powder is used for producing products of refractory materials with high erosion resistance, high thermal shock resistance and special shapes by 3D printing and production process thereof, α -Al is mixed according to proportion2O3Powder, ZrO2Powder β -Si3N4Powder, Si powder, CeO2Powder of MgAl2O4Adding water into the powder and the polycarboxylic acid powder, wet-grinding until D90 is 1-2 mu m, drying to obtain mixed powder, and strongly mixing and grinding the mixed powder and the acrylate according to a proportion to obtain the ceramic raw material powder for 3D printing. Printing the special-shaped refractory material product by using a 3D printer, wherein the forming temperature is 130-190 ℃, the pressure is 2-8 MPa, and the special-shaped refractory material product is prepared by ultraviolet curing and sintering. The production process has the advantages of no need of isostatic pressing and post-processing, and the use advantage of the invention is suitable for clean steel production, no pollution to ultra-clean ultra-low carbon steel, and is suitable for functional parts in the fields of continuous casting functional refractory materials, ultra-clean ultra-low carbon steel and the like. The patented technology has limitation on specific product materials, and has no universality aiming at the molding of refractory materials with wide raw material sources.
Patent "CN 110475842A" relates to a refractory product and a method for manufacturing the same. The refractory article includes an outer side and an inner side. The outer side defines a plurality of exterior surfaces of the refractory article that are exposed to the environment. The inner portion is formed inside the outer portion. The outer and inner portions are both porous and made of a refractory material. The outer portion has a first material density and the inner portion has a second material density. The first material density is less than the second material density. The method of making a refractory article comprises: forming a refractory article from the refractory material by 3D printing; wherein the formed refractory article is porous.
The patent "CN 108409311A" provides a multi-component 3D printing extrusion molding material, the molding material is formed by mixing N components, N is more than or equal to 2, the N components all comprise refractory material powder, a dispersing agent and water, at least one of the N components further comprises a coagulation regulator, any m of the N components further comprises a binder, and at least one of the rest N-m components further comprises a curing agent. The invention not only can prolong the quality guarantee period of the molding material, but also can provide series products applied under different curing time or different temperature conditions.
Patent "CN 106984771A" a method for improving 3D prints high temperature strength of sand mould/psammitolite belongs to the 3D and prints the field, and concrete content includes: 1)3D printing a sand mold and a sand core; 2) uniformly mixing and stirring a binder and a refractory material according to the mass ratio of 1 (0-1), and adding water to prepare a binder diluent with a Baume degree of 1-60; 3) vacuum infiltration, namely completely immersing the 3D printing sand mold and the sand core into a binder diluent, placing the sand mold and the sand core into a vacuum box for negative pressure exhaust treatment, keeping the vacuum state at 10-80 ℃, and opening an air valve for pressurization after the gas in the sand mold/sand core and the binder diluent is completely exhausted and floats upwards; 4) and (3) cleaning the surface of the sand mold/sand core, dehydrating, curing, and finally coating and hanging conventional coating, baking and casting, and performing ultrasonic demolding. The method has the advantages of simple process, low cost, good controllability, good collapsibility maintenance, improvement on the precision and complexity of the sand mold/sand core structure and full play of the molding advantages of 3D printing. The patent is mainly related to a preparation process of a 3D sand mold, and does not relate to a specific use method of the 3D sand mold in the field of refractory material molding.
Disclosure of Invention
The invention aims to provide a preparation method of a rapidly-molded complex special-shaped refractory material, which can be used for preparing a special-shaped refractory material product with a complex shape, and has high preparation precision and controllable dimensional tolerance of +/-0.3 mm.
The invention adopts the following technical scheme for achieving the purpose:
a method for rapidly forming complex heterotype refractory material comprises sequentially adding 60-80% of granular raw material, 20-40% of fine powder raw material and binder into a mixing machine to mix into castable, injecting the mixed castable into a 3D printing sand mold on a vibration table, and performing vibration forming;
the vibration frequency can be adjusted to be more than 50Hz in the vibration process, and the eccentric block of the vibration motor can be adjusted according to the size of a product to adjust the vibration intensity, so that high-frequency low-intensity vibration is realized;
preparing a castable: putting the refractory raw materials into a mixing machine, dry-stirring for 5-10 min, adding a bonding agent, and stirring for 15-20 min to prepare a castable;
vibration molding: placing the mould on a vibration table for fixing, injecting the mixed casting material into a 3D printing sand mould placed on the vibration table, starting the vibration table, and adjusting the vibration frequency and the vibration amplitude according to the shape complexity and the size of the prepared product before molding;
and (5) maintenance: after vibration molding, placing the product for 12-24 hours to fully cure the bonding agent and endow the blank with higher strength;
drying: drying the product according to the thickness and different combination systems;
according to the design of different product molds, performing demolding treatment or lost foam treatment on an outer mold and an inner mold of the 3D printing sand mold; the temperature of the lost foam treatment is 300-400 ℃, and the atmosphere is air; and (3) adopting proper heat treatment temperature to the refractory casting product according to the requirements of customers and the service performance of the product to finally obtain the product.
The material of the 3D printing sand mold can be one of quartz sand, ferrochrome sand and ceramsite sand.
The 3D printing sand mold generally includes an outer mold and an inner mold.
The 3D printing sand mold outer mold and the inner mold can be repeatedly used or used as a lost foam according to specific product characteristics.
The heat treatment temperature of the 3D printing sand mold lost foam is 300-400 ℃.
The preparation method is mainly characterized in that the blank prepared by the method is not limited by the shape, the three-dimensional model design is applied to the 3D printing of the sand mold, the mold manufacturing period is short, the time is generally from several hours to tens of hours according to the complexity of the sand mold, the rapid molding can be completed aiming at small-batch and personalized customized customer orders, the size is accurate, and the risks such as deformation and cracking are avoided.
The invention has the advantages that the manufacturing period of the mould of the complex special-shaped product is short, the manufacturing precision is high, so that the whole production period of the corresponding complex special-shaped refractory material is short in time consumption and low in cost, and the manufacturing capability and the precision control level on the composite structural component with complex shape are greatly improved. The 3D printing sand mold is applied to manufacturing of complex special-shaped refractory materials, a traditional refractory material mold manufacturing mode is overturned, and the 3D printing sand mold has great development potential in the aspects of manufacturing of complex-structure and composite-performance ceramic components, integrated molding, light-weight design, shortening of research and development period, reduction of product cost and the like. Compared with the traditional wood die or steel die, the 3D printing sand die has low density, can reduce the labor intensity of field workers, can save a large amount of wood and special metal materials due to convenient recycling, particularly needs heat treatment for obtaining good toughness and surface hardness, undoubtedly increases the energy consumption and the emission of atmospheric pollutants, and simultaneously needs to consume precious rare metals and other resources. Therefore, the method for quickly forming the complex special-shaped refractory material has the characteristics of rapidness and high efficiency in the aspect of service of complex special-shaped refractory material manufacturing, and has the advantages of good collapsibility, no structural stress release and obvious advantage of improving the manufacturing capability of the refractory material with the complex special-shaped inner cavity because the mold for 3D printing the sand mold has the characteristic of high specific strength and is used as a lost foam.
Detailed Description
The invention is described with reference to specific embodiments;
example 1:
the pump case appearance is manufactured, quartz sand materials are selected for sand molds of the 3D printing mold, the mold consists of an outer mold and a disappearing inner mold, the pouring materials are clay combined silicon carbide refractory pouring materials, the used proportion is that 3-0mm silicon carbide coarse particles account for 65 percent, powder materials such as-320-mesh silicon carbide and clay account for 35 percent, and the disappearing inner mold treatment temperature is 400 ℃. The cast product has smooth and fine appearance and accurate shape and size.
Example 2:
the impeller shape is manufactured, a chrome-iron sand material is selected for a sand mold of a 3D printing mold, the mold consists of an outer mold and a disappearing inner mold, the casting material is an oxide combined silicon carbide refractory casting material, the used proportion is that the proportion of coarse silicon carbide particles with the size of 3-0mm accounts for 70 percent, the proportion of powder materials such as-320 meshes of silicon carbide, metal silicon and the like accounts for 30 percent, the processing temperature of the disappearing inner mold is 350 ℃, and the product is free of defect and deformation.
Example 3:
making into flying saucer shape. The sand mould of the 3D printing mould is made of ceramsite sand, the mould is provided with an independent outer mould, the casting material is alumina casting material, the used proportion is 68 percent of coarse alumina particles with the particle size of 4-0mm, 32 percent of powder with the particle size below-200 meshes, and the treatment temperature of the disappearing inner mould is 300 ℃.
Claims (5)
1. A method for quickly forming a complex special-shaped refractory material is characterized by comprising the following steps: sequentially adding 60-80% of particle raw materials, 20-40% of fine powder raw materials and a binding agent into a mixing machine to be mixed into a casting material, injecting the mixed casting material into a 3D printing sand mold placed on a vibration table, and performing vibration molding;
the vibration frequency can be adjusted to be more than 50Hz in the vibration process, and the eccentric block of the vibration motor can be adjusted according to the size of a product to adjust the vibration intensity, so that high-frequency low-intensity vibration is realized;
preparing a castable: putting the refractory raw materials into a mixing machine, dry-stirring for 5-10 min, adding a bonding agent, and stirring for 15-20 min to prepare a castable;
vibration molding: placing the mould on a vibration table for fixing, injecting the mixed casting material into a 3D printing sand mould placed on the vibration table, starting the vibration table, and adjusting the vibration frequency and the vibration amplitude according to the shape complexity and the size of the prepared product before molding;
and (5) maintenance: after vibration molding, placing the product for 12-24 hours to fully cure the bonding agent and endow the blank with higher strength;
drying: drying the product according to the thickness and different combination systems;
according to the design of different product molds, the outer mold and the inner mold of the 3D printing sand mold are subjected to demolding treatment or lost mold treatment.
2. The method for rapidly forming the complex-shaped refractory material according to claim 1, wherein the method comprises the following steps: the material of the 3D printing sand mold can be one of quartz sand, ferrochrome sand and ceramsite sand.
3. The method for rapidly forming the complex-shaped refractory material according to claim 1, wherein the method comprises the following steps: the 3D printing sand mold generally includes an outer mold and an inner mold.
4. A method for rapid prototyping of complex-shaped refractories as set forth in claim 3, wherein: the 3D printing sand mold outer mold and the inner mold can be repeatedly used or used as a lost foam according to specific product characteristics.
5. The method for rapidly forming the complex-shaped refractory material according to claim 1, wherein the method comprises the following steps: the heat treatment temperature of the 3D printing sand mold lost foam is 300-400 ℃.
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| CN202010509818.1A CN111592368A (en) | 2020-06-08 | 2020-06-08 | Rapid forming method of complex special-shaped refractory material |
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| CN202010509818.1A CN111592368A (en) | 2020-06-08 | 2020-06-08 | Rapid forming method of complex special-shaped refractory material |
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Citations (6)
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| CN104226915A (en) * | 2014-09-26 | 2014-12-24 | 衡阳中钢衡重铸锻有限公司 | Casting method of hollow shaft and casting mold |
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| US20160158828A1 (en) * | 2013-08-30 | 2016-06-09 | Asahi Organic Chemicals Industry Co., Ltd. | Method of forming laminar mold |
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2020
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| US20160158828A1 (en) * | 2013-08-30 | 2016-06-09 | Asahi Organic Chemicals Industry Co., Ltd. | Method of forming laminar mold |
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